Unitized load covers

ABSTRACT

A unitized load cover includes a top panel, at least one first side panel coupled to the top panel and extending downward from the top panel, and at least one second side panel coupled to the top panel and extending downward from the top panel. One of the second side panels can be next to or across from one of the first side panel. An average thickness of the first side panel is greater than an average thickness of the second side panel, where the average thickness of a panel is a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel. The first side panel, second side panel, and top panel define a cavity configured to receive at least one unitized load.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 62/878,007, filed on Jul. 24, 2019, the entire disclosure of which is hereby incorporated by reference.

TECHNICAL FIELD

Embodiments of the present disclosure generally relate to unitized load covers, in particular unitized load covers for thermally protecting goods shipped in standard shipping containers.

BACKGROUND

Many goods introduced into commerce are shipped to domestic and international customers using standard shipping containers, which are generally metal rectangular boxes having standard length and width dimensions that comply with international standards. The goods are loaded into the shipping container, the shipping container is closed and sealed, and the shipping container is transported to its final destination via ship, rail, truck, or other transportation method. In many cases, the shipping containers pass through warm temperature climates and may absorb solar radiation energy from sunlight, both of which may cause heat transfer through the metal walls and into the headspace of the shipping container. The resulting heat flux into the goods contained within the shipping container may produce peak temperatures within the shipping container that can cause alteration of the goods contained within the shipping container, such as changes in physical properties or chemical composition.

SUMMARY

Accordingly, ongoing needs exist for unitized load covers capable of thermally protecting goods transported in standard shipping containers by reducing heat flux from the walls and headspace of a standard shipping container into the goods stored therein. A further need exists for unitized load covers that provide improved thermal insulation while still conforming to space limitations and allowing for two unitized loads to be positioned side-by-side within the shipping container.

One or more of these needs are met by various embodiments of the unitized load covers of the present disclosure. The unitized load covers of the present disclosure may include thicker side panels arranged on the sides of the unitized load facing outwards towards the container walls and thinner side panels between the unitized loads. The thicker side panels positioned on the outer facing sides of the goods facing the container walls may provide improved thermal insulation to reduce heat transfer from the walls of the shipping container to the unitized load, thereby limiting the impact of the peak temperatures experienced inside the shipping container. Heat transfer between adjacent unitized loads in an aggregated collection of unitized loads may be minimal compared to the heat transfer between the walls of the container and the unitized load. Positioning the thinner side panels of the unitized load cover between the unitized loads may allow for the overall width contribution of the unitized load cover to remain the same. By making the outer panels thicker and the inner panels thinner, the unitized load cover can improve insulation of the unitized load from exterior heat sources while conforming to the space limitations within the shipping container to preserve the ability to fit two unitized loads with the unitized load covers side-by-side within the shipping container.

According to one or more aspects, a unitized load cover may include a top panel, at least one first side panel coupled to the top panel and extending downward from the top panel, and at least one second side panel coupled to the top panel and extending downward from the top panel. The at least one second side panel may be next to or across from the at least one first side panel. An average thickness of the first side panel may be different from an average thickness of the second side panel, where the average thickness of a panel is a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel. The at least one first side panel, the at least one second side panel, and the top panel may define a cavity configured to receive at least one unitized load.

According to one or more other aspects, a method of thermally insulating a unitized load during shipment may include placing a unitized load cover over the unitized load so that the unitized load is disposed within a cavity defined by the unitized load cover. The unitized load cover may include a top panel, at least one first side panel coupled to the top panel and extending downward from the top panel, and at least one second side panel coupled to the top panel and extending downward from the top panel. The at least one second side panel may be next to or across from the at least one first side panel. An average thickness of the first side panel may be different from an average thickness of the second side panel, where the average thickness of a panel is a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel. The at least one first side panel, the at least one second side panel, and the top panel may define a cavity configured to receive one unitized load. The unitized load cover may be arranged on the unitized load so that, when the unitized load is loaded into a shipping container, the at least one first side panel of the unitized load cover may face towards a container wall of the shipping container. The at least one first side panel may be operable to reduce heat transfer from an interior of the shipping container through the unitized load cover, thereby thermally insulating the unitized load.

Additional features and advantages of the described embodiments will be set forth in the detailed description, which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the described embodiments, including the detailed description, which follows, the claims, as well as the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

FIG. 1 schematically depicts a cross-sectional view of commercially available unitized load cover, in accordance with the prior art;

FIG. 2 graphically depicts surface temperature (y-axis) of a unitized load cover installed on a unitized load within a shipping container as a function of time (x-axis) for the top surface, outside surface, and inside surface of the unitized load cover;

FIG. 3A schematically depicts a front perspective view of a unitized load cover, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 3B schematically depicts a cross-sectional view of the unitized load cover of FIG. 3A taken along reference line 3B-3B, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 4A schematically depicts a top cross-sectional view of the unitized load cover of FIG. 3A, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 4B schematically depicts a top cross-sectional view of another embodiment of a unitized load cover, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 4C schematically depicts a top cross-sectional view of still another embodiment of a unitized load cover, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 5 schematically depicts a partial cross-sectional view of the unitized load covers of FIG. 3B installed on unitized loads arranged side-by-side within a shipping container, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 6 schematically depicts a top cross-sectional view of another embodiment of unitized load covers installed on a plurality of unitized loads within a shipping container, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 7 schematically depicts a top cross-sectional view of yet another embodiment of unitized load covers installed on a plurality of unitized loads within a shipping container, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 8 schematically depicts a top cross-sectional view of still another embodiment of unitized load covers installed on a plurality of unitized loads within a shipping container, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 9 schematically depicts a front view of another embodiment of a unitized load cover, in accordance with one or more embodiments shown and described in the present disclosure;

FIG. 10 schematically depicts a partial cross-sectional view of the unitized load cover of FIG. 9 installed on two unitized loads arranged side-by-side in a shipping container, in accordance with one or more embodiments shown and described in the present disclosure; and

FIG. 11 schematically depicts a front view of the unitized load cover of FIG. 9 installed on two unitized loads arranged side-by-side in a shipping container, in accordance with one or more embodiments shown and described in the present disclosure.

The dimensions in various figures are not intended to be to scale and may be exaggerated in certain respects for purposes of illustration.

DETAILED DESCRIPTION

Embodiments of the present disclosure are directed to unitized load covers for thermally insulating unitized loads during storage and transport of the unitized loads, such as transportation of the unitized loads in standard shipping containers. Referring to FIGS. 3A and 3B, an embodiment of the unitized load cover 40 of the present disclosure is schematically depicted. The unitized load cover 40 may include a top panel 50, at least one first side panel 60 coupled to the top panel 50 and extending downward (e.g., in the −Z direction of the coordinate axis of FIGS. 3A and 3B) from the top panel 50, and at least one second side panel 70 coupled to the top panel 50 and extending downward from the top panel 50. The first side panels 60 and second side panels 70 may be coupled and/or coupleable to each other and to the top panel 50 to form an open-sided container or cover. The top panel 50, the at least one first panel 60, and the at least one second panel 70 may define a cavity configured to receive at least one unitized load 20 therein. The second panel 70 may be next to or across from the first panel 60. A first thickness t₁ of the first side panel 60 may be greater than a second thickness t₂ of the second side panel 70. The unitized load covers 40 of the present disclosure may allow for a greater thickness of insulation on the sides of the unitized loads facing the walls of the shipping container while conforming to the space limitations within the shipping container.

As used herein, the term “width” may refer to a dimension of an object measured in a direction generally parallel to the width W_(S) of the shipping container 10 as shown in FIG. 1. “Width” in the present disclosure may generally refer to distance measured in the +/−X direction of the coordinate axis in the Figures.

As used herein, the term “insulate” generally refers to thermal insulation in which the resistance to the flow of heat through a structure is increased in order to decrease the heat flux through the structure (e.g., film).

As used herein, the term “shipping container” refers to an intermodal freight container having a standard dimensions sufficient to contain a plurality of unitized loads.

Referring to FIG. 1, a standard shipping container 10 is depicted with two unitized loads 20 having commercially available pallet covers 30 installed thereon. The unitized loads 20 include a pallet 22 and one or plurality of goods 24 disposed on and supported by the pallet 22. The goods 24 may include a single good, plurality of goods, or semi-bulk goods contained in bulk packaging, such as tote bags, bulk bins, bulk boxes, liquid totes, drums, flexible intermediate bulk containers, or other bulk packaging. The goods 24 may also include a plurality of goods contained in one or a plurality of packages, such as but not limited to fiberboard or corrugated boxes, plastic boxes, bags (e.g., plastic, paper, natural fiber), or pails that are stacked on the pallet 22. The goods 24 and/or packages of goods 24 may be wrapped in a polymer film, such as but not limited to shrink-wrap. Other goods 24 in various other types of containers and packaging are contemplated. In some embodiments, the goods 24 may include polymers, such as elastomers, in the form of a plurality of pellets, which may be flowable. The polymer pellets may be packaged in boxes, bags, or flexible intermediate bulk containers.

Standard shipping containers 10 have a standard inside width W_(S). As used herein the inside width W_(S) of the shipping container 10 may refer to the minimum distance between the container walls 14 on the inside of the shipping container 10 and does not include the thickness of any coverings coupled to the container walls 14. The pallets 22 of the unitized load 20 may be sized to fit two unitized loads 20 side-by-side within the shipping container 10. The size of the pallets 22 may be determined according to parameters of the manufacturing, warehouse, or logistics processes. In some embodiments, the pallets 22 may have width W_(P) selected to maximize the volume of the shipping container 10. For example, the pallets 22 may have a width W_(P) such that two pallets arranged side-by-side have a combined width (2×W_(P)) that is as close as possible to the inside width W_(S) of the shipping container 10, such as within 5%, within 4%, within 3%, or even within 2% of the inside width W_(S) of the shipping container 10.

As previously discussed, the shipping container 10 may be exposed to solar radiation from the sun and high temperatures during storage and transit from the shipping location to the destination. For example, the shipping container 10 may be transported through a tropical climate with ambient temperatures in excess of 35° C. or even 40° C. Additionally, the shipping container 10 may absorb solar radiation energy, which may cause the interior of the shipping container 10 to further increase in temperature. As shown in FIG. 1, the heat flux from the ambient atmosphere and/or heat absorbed as solar energy may be conducted through the walls 14 of the shipping container 10 and/or transferred by convection into the headspace 12 of the shipping container 10. The heat flux through the walls 14 and into the headspace 12 of the shipping container 10 is indicated in FIG. 1 and throughout the Figures by reference number 16. Heat flux into shipping container 10 during daytime hours can produce peak temperatures of greater than or equal to 50° C., greater than or equal to 60° C., or even greater than or equal to 70° C.

The peak temperatures caused by heat flux 16 into the goods 24 of the unitized loads 20 from the container walls 14 and/or the headspace 12 of the shipping container 10 may cause undesirable changes in the goods 24, such as changes in physical properties and/or chemical composition. For example, the goods 24 may include various polymers, which are often sold and transported in the form of pellets intended to be flowable from the packaging into the customer's process upon arrival at a customer's location. However, when transporting polymer pellets in a shipping container 10, the heat flux 16 in the shipping container 10 may cause the temperature of the polymer pellets to increase above the softening temperature of the polymer. Softening temperatures for typical elastomeric polymers may be in a range of from 35° C. to 45° C., which are less than peak temperatures often experienced in the shipping containers 10 during transit and storage. The peak temperatures in excess of 50° C. in the shipping container 10 may, therefore, cause the polymer pellets to soften and fuse together to form solid agglomerates of polymer pellets, which may be referred to as blocking or massing of the polymer pellets. The solid masses or agglomerates of polymer pellets are more difficult for the polymer customer to use compared to the flowable pellets, which may render a portion of the polymer pellets unusable. Thus, blocking and massing of polymer pellets may result in loss of product. Other types of undesirable changes, such as spoliation, changes in physical properties, and/or changes in chemical composition of the goods 24, may also result from the peak temperatures caused by heat flux 16 from the shipping container 10 to the goods 24.

Various methods may be employed to reduce the amount of heat transferred from the shipping container 10 to the goods 24. Refrigerated shipping containers may be used to remove the heat transferred to the shipping container 10 and maintain the temperature below the target temperature for the goods 24. However, refrigerated shipping containers can greatly increase the shipping costs of the goods 24. Referring again to FIG. 1, commercially available pallet covers 30 may be placed over the unitized load 20 to insulate the goods 24 from the heat transferred into the shipping container 10. The commercially available pallet covers 30 may be placed over the unitized load 20 so that the goods 24 and at least a portion of the pallet 22 are contained within the commercially available pallet cover 30. The commercially available pallet covers 30 include a top section 32 and a plurality of sides 34 coupled to the top section 32 and extending downward from the top section 32. For commercially available pallet covers 30, all of the sides 34 have the same thickness. For example, the thickness t_(A) of the sides 34 between unitized loads 20 is the same as the thickness t_(B) is of the sides 34 facing outward toward the container walls 14 of the shipping container 10. Thus, for the commercially available pallet covers 30 having all sides 34 with the same thickness, each side 34 of the commercially available pallet cover 30 has generally the same thermal insulation value. The width contribution of a single commercially available pallet cover to the overall width of two side-by-side unitized loads 20 placed in a shipping container 10 can be expressed as W_(C)=(t_(A)+t_(B)), where t_(A)=t_(B). The total width contribution for two commercially available pallet covers 30 on side-by-side unitized loads 20 is therefore W_(C)=4×t_(A)=4×t_(B). Typical commercially available pallet covers 30 may have an average thickness of the sides 34 (t_(A)=t_(B)) of from 0.25 inches to 2.0 inches (6.35 millimeters (mm) to 50.8 mm) with a possible total width contribution of the cover 30 of from 1.0 inches to 6.0 inches (25.4 mm-152.4 mm), as installed on two side-by-side unitized loads 20 placed in a shipping container 10.

However, the space available within the shipping container 30 for accommodating the current commercially available pallet covers 30 is limited. As previously discussed, the width W_(P) of each of the pallets 22 and the width W_(S) of the shipping container 10 are generally fixed, which means that the amount of space left over and available for accommodating the sides 34 of commercially available pallet covers 30 is equal to the difference between the width W_(S) of the shipping container 10 and two times the width W_(P) of the pallets 22. The difference between the width W_(S) of the shipping container 10 and two times the width W_(P) of the pallets 22 may be less than 4 inches (101.6 mm), less than or equal to 3.5 inches (88.9 mm), or even less than or equal to 3 inches (76.2 mm). Thus, the width contribution of the sides 34 of the pallet covers 30 may be limited by the following expression: W_(C)≤W_(S)−2×W_(P). The thermal insulation value of an insulating material forming the sides 34 of the commercially available pallet cover 30 is directly proportional to the thickness of the insulating material. The space limitation within the shipping container 10 may prevent the sides 34 of the commercially available pallet covers 30 from having a thickness of insulation material needed to provide sufficient thermal insulation against the transfer of heat from the shipping container 10 to the goods 24. Increasing the thickness of the pallet covers 30 may result in tearing of the covers 30, increased loading time of the shipping containers 10, and/or decreased effectiveness of the insulation of the pallet covers 30 due to compression of the insulation materials. For the case of transporting goods 24 comprising polymer pellets, it has been found that the thickness of the sides 34 of commercially available pallet covers 30 is not sufficient to thermally insulate the polymer pellets to reduce or prevent softening, melting, or other changes to the polymer pellets.

It has been found that the heat flux from the shipping container 10 into the goods 24 comes mainly from the container walls 14 and from the headspace 12 of the shipping container 10. It was also found that when the unitized loads 20 are clustered together side-by-side in the transverse and longitudinal directions (i.e., +/−X and +/−Y directions, respectively) to form an array centered within the shipping container 10, the unitized loads 20 can be self-insulating at the inner surfaces between the unitized loads 20. When the unitized loads 20 in the clustered array are close together or in contact, the heat flux from radiation is insignificant and the heat flux from conduction is minimized due to the reduced ability of heated air from the headspace 12 of the shipping container 10 into in to the top surface of the unitized load 20. As long as the unitized loads 20 in the clustered array are placed in close proximity to each other (e.g., in contact or nearly in contact), the heat flux into each of the unitized loads 20 from between the unitized loads 20 is minimal compared to the heat flux from the container walls 14 to the outer surfaces of the unitized load and to the heat flux from the headspace 12 of the shipping container 10 into the top surface of the unitized load 20. Referring to FIG. 2, the temperatures of the various outer surfaces of commercially available pallet covers 30 installed on the unitized loads 20 are shown as a function of time. For FIG. 2, a plurality of commercially available pallet covers 30 were installed on a plurality of unitized loads 20, which were then arranged in close proximity to each other in a side-by-side array inside a standard shipping container 10. Temperature sensors were placed on the top surface of the cover 30, the side of the cover 30 facing the container wall 14, and the side of the cover 30 facing away from the container wall 14 and inward toward another unitized load 20. The shipping container 10 was placed outside where the shipping container 10 could be subjected to atmospheric temperature and periods of sunlight for an extended period of time. The temperatures of each of the surfaces were measured and recorded over a period of days. Reference number 202 indicates the temperature of the top surface of the cover 30, reference number 204 indicates the temperature of the side of the cover 30 facing outward towards the container wall 14, and reference number 206 indicates the temperature of the side of the cover 30 facing away from the container wall 14 and towards another unitized load 20.

As shown in FIG. 2, the greatest temperatures occur at the top surface of the pallet cover 30 (data series 202 in FIG. 2) during daylight hours. The vertical dimension (e.g., dimension in the +/−Z direction of FIG. 1) of the unitized load 20 is not constrained by the dimensions of the shipping container 10. Therefore, additional insulation can be added to the top of the unitized load 20 without being limited by space constraints. FIG. 2 also shows that the temperature of the side of the pallet cover 30 facing the container wall 14 (data series 204) also increases greatly during the daylight hours, when the shipping container 10 is exposed to sunlight. However, the temperature of the inside surface facing away from the container wall 14 (data series 206 in FIG. 2) does not change much as a function of time. This confirms that the inside surfaces of the unitized loads 20 that face away from the container wall 14 and towards another of the unitized loads 20 are self-insulating and do not experience a great amount of heat flux between unitized loads 20.

The present disclosure is directed to unitized load covers 40 that take advantage of the minimal heat flux between the unitized loads 20 to re-allocate insulation thickness from the areas between unitized loads 20 to the areas on the outside of the unitized loads 20 facing towards the container walls 14. Referring to FIGS. 3A and 3B, as previously discussed, the unitized load covers 40 of the present disclosure may include a top panel 50 and four side panels, which may include at least one first side panel 60 and at least one second side panel 70. The first side panel 60 may be a side of the unitized load cover 40 facing towards the container wall 14 and may have a first thickness t₁ that is greater than a second thickness t₂ of the second side panel 70, which may be a side of the unitized load cover 40 facing away from the container wall 14. Due to minimal heat flux between unitized loads 20 arranged in close proximity in an array within the shipping container 10, the second thickness t₂ of the second side panels 70 disposed between the unitized loads 20 can be reduced while the first thickness t₁ of the first side panels 60 facing towards the container walls 14 can be increased. Thus, the different panel thicknesses of the side panels 60, 70 of the unitized load covers 40 of the present disclosure may enable thicker thermal insulation to be positioned at the outer sides of the unitized loads 20 while reducing the thickness of insulation between pallets in order to conform to the space limitations within the shipping container. In other words, the greater first thickness t₁ of the first side panels 60 may provide greater insulation between the unitized loads 20 and the container walls 14 while the thinner second thickness t₂ may reduce the overall width contribution of the unitized load cover 40 to conform to the space restrictions within shipping container 10.

Referring to FIG. 3B, the top panel 50 may have a top surface 52 facing upward (e.g., in the +Z direction of the coordinate axis in FIG. 3B) and a bottom surface 54 facing vertically downward (e.g., in the −Z direction of the coordinate axis in FIG. 3B). Referring to FIG. 5, when the unitized load cover 40 is installed on the unitized load 20 placed in the shipping container 10, the top surface 52 of the top panel 50 may face towards the headspace 12 of the shipping container 10 (i.e., in the +Z direction of the coordinate axis of FIG. 3B), and the bottom surface 54 may face towards the unitized load 20 (i.e., in the −Z direction of the coordinate axis of FIG. 3B). Referring again to FIGS. 3A and 3B, the top panel 50 may additionally include a plurality of edges 56 forming a peripheral boundary of the top panel 50 proximate to which each of the side panels (first side panels 60, second side panels 70) may be coupled.

The top panel 50 may have a shape that conforms to a shape of a unitized load 20, when the unitized load 20 is view in a top view. The top panel 50 may have a length and width that conform to a length and width of the unitized load 20, such as a length and width of the pallet 22 of the unitized load 20 and/or a length and width of the collection of goods 24 supported by the pallet 22. In some embodiments, the top panel 50 may have a width W_(T) that is greater than or equal to the width W_(P) of the pallet 22 or unitized load 20 (FIG. 1), where the width W_(T) of the top panel 50 is the dimension of the top panel 50 measured in a direction parallel to the width W_(S) of the shipping container 10 (FIG. 1). In some embodiments, the goods 24 may be contained within a flexible intermediate bulk container supported on the pallet 22, and the top panel 50 may have a length and width sufficient to accommodate the dimensions of the flexible intermediate bulk container. The top panel 50 may have a square shape, rectangular shape, polygonal shape, or other shape. The top panel 50 may have an average thickness t_(T). The average thickness t_(T) of the top panel 50 may be the total distance between the top surface 52 and the bottom surface 54 of the top panel 50 averaged over the entire surface area of the top panel 50 when the unitized load cover 40 is installed on the unitized load 20 and loaded into the shipping container 10. Since the height of the unitized load 20 (e.g., measurement in the +/−Z direction of the coordinate axis of FIG. 3B) is not generally constrained by the vertical dimensions of the interior of the shipping container 10, the average thickness t_(T) of the top panel 50 may be any thickness suitable for reducing heat flux 16 from the headspace 12 of the shipping container 10 to the unitized load 20. In some embodiments, the top panel 50 may have an average thickness of from 0.25 inches (6.35 mm) to 5.0 inches (124 mm), such as 0.25 inches (6.35 mm) to 4.0 inches (101.6 mm), 0.25 inches (6.35 mm) to 3.0 inches (76.2 mm), or even 0.5 inches (12.7 mm) to 5.0 inches (127 mm), where the average thickness of the top panel 50 is determined as installed on the unitized load 20 with the unitized load 20 loaded into the shipping container 10.

Referring again to FIGS. 3A and 3B, the unitized load covers 40 may include at least four side panels that include at least one first side panel 60 and at least one second side panel 70. The top panel 50, first side panels 60, and second side panels 70 may define a cavity configured to receive a unitized load 20 within the cavity. The unitized load cover 40 may include one or a plurality of first side panels 60, such as 1, 2, or 3 first side panels 60. In some embodiments, the unitized load cover 40 may have more than three first side panels 60 such as when the shape of the top panel 50 has more than four edges 56. The first side panels 60 may include a top edge 61 and two vertical edges 62 (i.e., vertical edges referring to edges parallel to the +/−Z direction of the coordinate axis in FIGS. 3A and 3B throughout this disclosure). Each of the first side panels 60 may have an inner surface 66 facing inward toward the cavity defined by the unitized load cover 40 and an outer surface 68 facing outward from the unitized load cover 40. The first side panels 60 may have an average first thickness t₁. The average first thickness t₁ each first side panel 60 may be the total distance between the inner surface 66 and the outer surface 68 of the first side panel 60 averaged over the entire surface area of the first side panel 60 when the unitized load cover 40 is installed on the unitized load 20 and loaded into the shipping container 10. Each of the first side panels 60 may be coupled and/or coupleable to the top panel 50 proximate one of the edges 56 of the top panel 50. In some embodiment, the top edge 61 of each of the first side panels 60 may be coupled and/or coupleable to the top panel 50 proximate one of the edges 56 of the top panel 50. Each of the first side panels 60 may extend downward (e.g., in the −Z direction of the coordinate axis of FIG. 3B) from the top panel 50.

The unitized load cover 40 may include one or a plurality of second side panels 70, such as 1, 2, or 3 second side panels 70. In some embodiments, the unitized load cover 40 may have more than three second side panels 70 such as when the shape of the top panel 50 has more than four edges 56. The second side panels 70 may include a top edge 71 and two vertical edges 72. Each of the second side panels 70 may have an inner surface 76 facing inward toward the cavity defined by the unitized load cover 40 and an outer surface 78 facing outward from the unitized load cover 40. The second side panels 70 may have an average second thickness t₂. The average second thickness t₂ of each second side panel 70 may be the total distance between the inner surface 76 and the outer surface 78 of the second side panel 70 averaged over the entire surface area of the second side panel 70 when the unitized load cover 40 is installed on the unitized load 20 and loaded into the shipping container 10. Each of the second side panels 70 may be coupled and/or coupleable to the top panel 50 proximate one of the edges 56 of the top panel 50. In some embodiment, the top edge 71 of each of the second side panels 70 may be coupled to and/or coupleable to the top panel 50 proximate one of the edges 56 of the top panel 50. Each of the second side panels 70 may extend downward (e.g., in the −Z direction of the coordinate axis of FIG. 3B) from the top panel 50.

Referring to FIGS. 4A through 4C, the first side panels 60 and the second side panels 70 may be arranged in various patterns. For example, the at least one second side panel 70 may be next to or across from the at least one first side panel 60. Each vertical edge 62 of each first side panel 60 may be coupled to the vertical edge 62 of another first side panel 60 or the vertical edge 72 of a second side panel 70. Likewise, each vertical edge 72 of each second side panel 70 may be coupled to the vertical edge 72 of another second side panel 70 or the vertical edge 62 of a first side panel 60. Referring to FIG. 4A, in some embodiments, the unitized load covers 40 may include two first side panels 60 and two second side panels 70. The two first side panels 60 may be coupled together proximate a vertical edge 62 of each of the first side panels 60. The two second side panels 70 may be coupled together proximate the vertical edges 72 of each of the second side panels 70. In this configuration, the unitized load cover 40 may be arranged on a unitized load 20 so that one first side panel 60 may be disposed at the side of the unitized load 20 facing towards the container walls 14 of the shipping container 10 and the other first side panel 60 may be disposed at the side of the unitized load 20 facing towards an end 18 (FIG. 6) of the shipping container 10.

Referring now to FIG. 4B, in some embodiments, the unitized load covers 40 may include a single first side panel 60 and a plurality of second side panels 70. The vertical edges 62 of the first side panel 60 may be coupled to the second side panels 70 proximate the vertical edges 72 of the second side panels 70. In these embodiments, the unitized load cover 40 may be arranged on unitized load 20 so that the first side panel 60 may be oriented towards the container wall 14 of the shipping container 10. The plurality of second side panels 70 may be coupled together at the vertical edges 72 not coupled to the first side panel 60 in order to form the other three sides of the unitized load cover 40. The second side panels 70 may be positioned on sides of the unitized loads 20 facing towards adjacent unitized loads 20.

Referring now to FIG. 4C, in some embodiments, the unitized load covers 40 may include a plurality of first side panels 60 and a single second side panel 70. The vertical edges 72 of the second side panel 70 may be coupled to the first side panels 60 proximate the vertical edges 62 of the first side panels 60. In these embodiments, the unitized load cover 40 may be arranged on the unitized load 20 so that the second side panel 70 may be oriented towards an adjacent unitized load 20 arranged side-by-side with the unitized load 20 and away from the container wall 14. The plurality of first side panels 60 may be coupled together at the vertical edges 62 not coupled to the second side panel 70 in order to form the other three sides of the unitized load cover 40. Thus, the first side panels 60 may then be disposed on the other three sides of the unitized load. In this configuration, some of the first side panels 60 end up disposed between the unitized loads 20 that are in a front to back relationship between the two ends 18 of the shipping container. Because the space inside the shipping container 10 is generally not limited in the longitudinal direction from end to end, the greater thickness of the first side panels 60 do not present a problem when disposed between unitized loads 20 that are next to each other in the longitudinal direction.

Any of the first side panels 60, the second side panels 70, or the top panel 50 may be coupled to and/or coupleable to any of the other panels in the manners previous described by one or more of stitching, adhesives, bonding, fasteners, or combinations of these. Fasteners may include hook and loop fasteners, zippers, buttons, snaps, magnetic strips, pins, tie straps, or any other suitable fastener, or combinations of fasteners known in the art. Additionally, although described herein as being coupled together, in some embodiments, the top panel 50, first side panels 60, and second side panels 70 may be produced in individual pieces that can be coupled together at the point of use. It is intended for the term “coupled” to include instances in which the panels are initially detached but are removeably coupleable to each other and must be coupled together by the user at the point of use to form a usable unitized load cover 40.

The top panel 50, the first side panels 60, the second side panels 70, or combinations of these, may be flexible, multi-layer structures having a plurality of layers. The plurality of layers of the panels 50, 60, 70 may include one or a plurality of structural layers and at least one insulating layer comprising an insulating medium. The structural layers may include polymer films or fabrics. The fabrics may include woven or unwoven fabrics made from natural fibers or synthetic fibers.

The polymer films or fabrics of the structural layers may be coated or uncoated. For example, in some embodiments, the polymer films or fabrics may be coated with a reflective coating to reflect infrared radiation away from the unitized load 20. In some embodiments, the polymer films or fabrics may be metalized to form a reflective surface on one side of the structural layer. Any known method for metalizing or coating the polymer films or fabrics of the structural layer may be employed.

In some embodiments, the first side panels 60, the second side panels 70, or both, may include a reduced-friction layer on the outer surface, the inner surface, or both. The reduced-friction layer may be a reduced-friction coating or a reduced-friction film having a coefficient of friction that is less than the structural layers or insulating media of the first side panels 60, the second side panels, or both. In some embodiments, the reduced-friction layer may be a reduced-friction coating applied to the outer surface, the inner surface, or both, of the first side panels 60 and/or the second side panels 70. The reduced-friction layers being operable to reduce friction between adjacent unitized load covers 40 during loading of the unitized loads 20 into the shipping container 10. The reduced-friction layers on the outer surfaces of the first side panels 60 and/or the second side panels may also reduce the friction between the unitized load covers 40 and the container walls 14 of the shipping container 10. The reduced-friction layers on the inner surfaces of the first side panels 60 and/or the second side panels 70 may also reduce friction between the inner surfaces and the goods 24 of the unitized load 20 during installation and removal of the unitized load cover 40 on the unitized load 20. For example, the reduced-friction layers on in the inner surfaces of the first side panels 60 and/or second side panels 70 may reduce friction between the unitized load cover 40 and the outer surface of shrink wrap, the outer surface of a flexible intermediate bulk container, or the outer surface of other packing containing the goods 24. The reduced friction may enable the unitized load cover 40 to be more easily installed on or removed from the unitized load 20.

The insulating medium may include a gas or a solid insulating material capable of reducing the rate of heat flux through the panel. In some embodiments, one or more of the top panel 50, the first side panel 60, or the second side panel 70 may include a plurality of structural layers separated by a gas, such as air, nitrogen, or other gas, where the gas provides an insulating effect by reducing conduction of heat through the region of the gas.

The insulating medium may be a solid insulating material, which may be a natural or synthetic insulating material. The insulating material may be in the form of a film, fabric, foam, sheet, or other physical form. The insulating materials may include, but are not limited to polypropylene, polyester, polyethylene, TYVEK®, fiberglass, glass wool, polyurethane, cellulose, urea, polystyrene, cardboard, other insulating material, or combinations of insulating materials. The top panel 50, the first side panels 60, and/or the second side panels 70 may include a plurality of structural layers and one or a plurality of insulating materials disposed between each of the structural layers. Other combinations of structural layers and insulating media are contemplated.

In some embodiments, each of the top panel 50, the first side panels 60, and the second side panels 70 may have a different construction, such as a different number of structural layers or a different type of insulating media. For example, the second side panels 70 may include a plurality of structural layers and a gas between each of the structural layers while the first side panels 60 may include one or a plurality of structural layers with solid insulating materials disposed between the structural layers to provide the greater thickness and improved insulation performance of the first side panels 60 compared to the second side panels 70. The top panels 50 may additionally have a different construction than either the first side panels 60 and/or the second side panels 70. In some embodiments, the top panel 50, the first side panels 60, the second side panels 70, or combinations of these, may have the same general construction and may only differ in the thickness of the insulating media between the structural layers. In some embodiments, one or more of the top panel 50, the first side panel 60, the second side panel 70, or combinations of these, may have the same general construction but may include one or more structural layers or insulating media that is different than the structural layers or insulating media of the other panels. In some embodiments, the top panel 50, the first side panels 60, and/or second side panels 70 may include a plurality of panels coupled together at the vertical edges or at the inner surface or outer surface of the panels.

As previously discussed, the insulating capabilities of the top panel 50, the first side panels 60, and the second side panels 70 may be proportional to the average thickness t_(T) of the top panel 50, the average first thickness t₁ of the first side panels 60, and the average second thickness t₂ of the second side panels 70, respectively. The average thickness of each of the top panel 50, first side panels 60, and/or the second side panels 70 may be modified by changing the construction of the panel and/or the thickness of the insulating media for the top panel 50, the first side panel 60, and the second side panel 70, respectively. To provide the additional insulation thickness at the side of the unitized load 20 facing the container wall 14 and maintain the total width contribution of the unitized load cover 40, the average first thickness t₁ of the first side panel 60 may be increased, and the average second thickness t₂ of the second side panel 70 may be decreased. Thus, the average first thickness t₁ of the first side panel 60 may be greater than the average second thickness t₂ of the second side panel 70. The total width contribution W_(C) of the unitized load cover 40 may therefore be equal to two times the sum of the average first thickness t₁ and the average second thickness t₂ (W_(C)=2×(t₁+t₂)) for two unitized loads 20 arranged side-by-side with each unitized load 20 covered by one unitized load cover 40.

A ratio of the average first thickness t₁ of the first side panels 60 to the average second thickness t₂ of the second side panels 70 may be greater than or equal to 1.25, such as greater than or equal to 1.5, greater than or equal to 1.75, or even greater than or equal to 2.0 when the unitized load covers 40 are installed on the unitized loads 20 and the unitized loads 20 are loaded into the shipping container 10 in a side-by-side array. The ratio of the average first thickness t₁ of the first side panels 60 to the average second thickness t₂ of the second side panels 70 may be from 1.25 to 100, such as from 1.50 to 50, or even from 1.5 to 25 when the unitized load covers 40 are installed on the unitized loads 20 and the unitized loads 20 are loaded into the shipping container 10 in a side-by-side array.

The first side panel 60 may have an average first thickness t₁ that is greater than the average second thickness t₂ of the second side panels 70 and greater than 0.20 inches (5.08 mm), greater than or equal to 0.25 inches (6.35 mm), greater than or equal to 0.5 inches (12.7 mm), greater than or equal to 0.75 inches (19.1 mm), or even greater than or equal to 1.0 inch (25.4 mm), where the average first thickness t₁ may be the total distance between the inner surface 66 and the outer surface 68 of the first side panel 60 averaged over the entire surface area of the first side panel 60 when the unitized load cover 40 is installed on the unitized load 20 and loaded into the shipping container 10. The first side panel 60 may have an average first thickness t₁ greater than the average second thickness t₂ of the second side panels 70 and less than or equal to 3.0 inches (76.2 mm), less than or equal to 2.75 inches (69.9 mm), or even less than or equal to 2.5 inches (127 mm), where the average first thickness t₁ is defined as previously described. The first side panel 60 may have an average first thickness t₁ of from 0.20 inches to 3.0 inches, from 0.5 inches to 3.0 inches, or from 0.5 inches to 2.5 inches and greater than the average second thickness t₂ of the second side panels 70, where the average first thickness t₁ is defined as previously described.

The second side panel 70 may have an average second thickness t₂ of less than the average first thickness t₁ of the first side panels 60 and greater than or equal to 0.031 inches (0.79 mm), greater than or equal to 0.1 inches (2.54 mm), or even greater than or equal to 0.25 inches (6.35 mm), where the average second thickness t₂ may be the total distance between the inner surface 76 and the outer surface 78 of the second side panel 70 averaged over the entire surface area of the second side panel 70 when the unitized load cover 40 is installed on the unitized load 20 and loaded into the shipping container 10. The second side panel 70 may have an average second thickness t₂ less than the average first thickness t₁ of the first side panels 60 and less than or equal to 1.0 inches (25.4 mm), less than or equal to 0.5 inches (12.7 mm), or even less than or equal to 0.3 inches (7.6 mm), where the average second thickness t₂ is defined as previously described. The second side panel 70 may have an average second thickness t₂ of from 0.031 inches (0.79 mm) to 1.0 inches (25.4 mm), from 0.10 inches to 0.5 inches, or even from 0.25 inches to 0.5 inches and less than the average first thickness t₁ of the first side panels 60, where the average second thickness t₂ is defined as previously described.

Referring to FIG. 5, two unitized loads 20 are depicted arranged side-by-side within the standard shipping container 10. As shown in FIG. 5, the headspace 12 of the shipping container 10 provides additional space above the unitized load 20 (e.g., in the +Z direction of the coordinate axis of FIG. 5) so that the vertical height of the unitized load 20 and unitized load cover 40 may not be limited by the height (e.g., dimension in the +/−Z direction of the coordinate axis of FIG. 5) of the shipping container 10. For this reason, the average thickness t_(T) of the top panel 50 is not necessarily limited by space restraints. In some embodiments, the average thickness t_(T) of the top panel 50 can be the same as the average first thickness t₁ of the first side panel 60 or the average second thickness t₂ of the second side panel 70. In other embodiments, the top panel 50 may have an average thickness t_(T) greater than or equal to the average first thickness t₁ of the first side panel 60, the average second thickness t₂ of the second side panel 70, or both. The greater average thickness t_(T) of the top panel 50 may provide additional thermal insulation against heat flux coming from the headspace 12 of the shipping container 10.

Referring again to FIG. 5, for the unitized load 20 on the left side of FIG. 5 (e.g., in the −X direction of the coordinate axis of FIG. 5), the unitized load cover 40 may be arranged on the unitized load 20 with the first side panel 60 facing towards the container wall 14 (e.g., facing in the −X direction of the coordinate axis of FIG. 5) and the second side panel 70 facing inwards (e.g., in the +X direction of the coordinate axis of FIG. 5) towards the adjacent unitized load 20 arranged side-by-side on the right-hand side of the shipping container 10. For the unitized load 20 on the right-hand side of FIG. 5 (e.g., in the +X direction of the coordinate axis of FIG. 5), the unitized load cover 40 may be arranged on the unitized load 20 with the first side panel 60 facing towards the container wall 14 (e.g., facing in the +X direction of the coordinate axis of FIG. 5) and the second side panel 70 facing inwards (e.g., in the −X direction of the coordinate axis of FIG. 5) towards the adjacent unitized load 20 arranged side-by-side on the left-hand side of the shipping container 10. Thus, the first side panels 60 of each of the unitized load covers 40 may be oriented facing the container walls 14 to provide additional thermal insulation against heat flux 16 from the container walls 14. The second side panels 70 of each of the unitized load covers 40 may be oriented inwards to face one another. The reduced average second thickness t₂ of the second side panels 70 between the unitized loads 20 may allow for additional space between the unitized loads 20 and the container walls 40 to accommodate the greater average first thickness t₁ of the first side panels 60.

For unitized loads 20 positioned proximate the ends of the shipping container 10, the unitized load cover 40 may have an additional first side panel 60 having the greater average first thickness t₁ oriented towards the end of the shipping container 10, the additional first side panel 60 proximate the end of the shipping container 10 may provide additional insulation on the side of the unitized load 20 facing towards the ends of the shipping container 10.

Referring now to FIGS. 6-8, the unitized load cover 40 may additionally include one or a plurality of third side panels 80, such as 1, 2, or 3 third side panels 80. In some embodiments, the unitized load cover 40 may have more than three third side panels 80, such as when the shape of the top panel 50 has more than four edges 56. The third side panels 80 may include a top edge (not shown) and two vertical edges (not shown). The third side panels 80 may have an inner surface 86 facing inward toward the cavity defined by the unitized load cover 40 and an outer surface 88 facing outward from the unitized load cover 40. The third side panel 80 may have an average third thickness t₃. The average third thickness t₃ may be the total distance between the inner surface 86 and the outer surface 88 of the third side panel 80 averaged over the entire surface area of the third side panel 80 when the unitized load cover 40 is installed on the unitized load 20 and loaded into the shipping container 10. The third side panels 80 may have an average third thickness t₃ that is different from the average first thickness t₁ of the first side panels 60 and the average second thickness t₂ of the second side panels 70. Each of the third side panels 70 may be coupled and/or coupleable to the top panel 50 proximate one of the edges 56 of the top panel 50. In some embodiment, the top edge of each of the third side panels 80 may be coupled and/or coupleable to the top panel 50 proximate one of the edges 56 of the top panel 50. Each of the third side panels 80 may extend downward from the top panel 50 similar to the first side panels 60 and/or second side panels 70.

The third side panel 80 may be a flexible, multi-layer structure having any of the features, characteristics, or attributes previously described herein for the top panel 50, the first side panel 60, and/or the second side panel 70. The third side panel 80 may be a flexible multi-layer structure having a construction that is the same as or different from the construction of one or more of the top panel 50, the first side panel 60, and/or the second side panel 70.

The third side panel 80 may have an average third thickness t₃ of greater than or equal to 0.25 inches (6.35 mm), or even greater than or equal to 0.5 inches (12.7 mm), where the average third thickness t₃ may be the total distance between the inner surface and the outer surface of the third side panel 80 averaged over the entire surface area of the third side panel 80 when the unitized load cover 40 is installed on the unitized load 20 and loaded into the shipping container 10. The third side panel 80 may have an average third thickness t₃ of less than or equal to 3.0 inches (76.2 mm), less than or equal to 2.5 inches (63.5 mm), or even less than or equal to 2.0 inches (50.8 mm), where the average third thickness t₃ is defined as previously described. The third side panel 80 may have an average third thickness t₃ of from 0.25 inches (6.35 mm) to 3.0 inches (76.2 mm), where the average third thickness t₃ is defined as previously described.

Referring now to FIG. 6, a top cross-sectional view of a plurality of unitized load covers 40 on unitized loads 20 loaded into a shipping container 10 is depicted. As shown in FIG. 6, the unitized load covers 40 may include one first side panel 60, one second side panel 70, and two third side panels 80. The unitized load covers 40 may be arranged on the unitized load 20 so that the first side panel 60 is facing outward towards the container wall 14, the second side panel 70 is facing inward toward the adjacent unitized load 20 arranged side-by-side therewith (i.e., between unitized loads 20 arranged side-by-side with respect to the +/−X direction of the coordinate axis in FIG. 7), and the third side panels 80 are positioned between the unitized loads 20 in the longitudinal direction (i.e., in the +/−Y direction of the coordinate axis in FIG. 6).

Referring to FIG. 7, in some embodiments, the unitized load covers 40 may include two first side panels 60 and two second side panels 70, as previously described herein. The unitized load covers 40 may be arranged on the unitized load 20 so that at least one of the first side panels 60 is facing outward towards the container wall 14 and at least one of the second side panels 70 is facing inward toward the adjacent unitized load 20 arranged side-by-side therewith (i.e., between unitized loads 20 arranged side-by-side with respect to the +/−X direction of the coordinate axis in FIG. 7). The unitized load covers 40 may also be arranged on the unitized loads 20 so that, for the unitized loads 20 proximate the ends 18 of the shipping container 10, the other one of the first side panels 60 is disposed on a side of the unitized load cover 40 facing towards the end 18 of the shipping container 10. Arranging the unitized load cover 40 so that the other first side panel 60 faces towards the end 18 of the shipping container 10 may provide additional insulation against heat flux from the ends 18 of the shipping container 10 and may reduce the transfer of heat to the unitized load 20 from the ends 18 of the shipping container 10.

Referring to FIG. 8, in some embodiments, the unitized load covers 40 may include two first side panels 60, one second side panel 70, and one third side panel 80. The unitized load covers 40 may be arranged on the unitized load 20 so that one of the first side panels 60 is facing outward towards the container wall 14. The unitized load covers 40 may also be arranged on the unitized loads 20 so that, for the unitized loads 20 proximate the ends 18 of the shipping container 10, the other one of the first side panels 60 is disposed on a side of the unitized load cover 40 facing towards the end 18 of the shipping container 10. The unitized load cover 40 may be arranged on the unitized load 20 so that the second side panel 70 faces inward toward the adjacent unitized load 20 arranged side-by-side therewith (i.e., between unitized loads 20 arranged side-by-side with respect to the +/−X direction of the coordinate axis in FIG. 8), and the third side panels 80 are positioned between the unitized loads 20 in the longitudinal direction (i.e., in the +/−Y direction of the coordinate axis in FIG. 6). For unitized loads 20 proximate one end 18 of the shipping container 10, the unitized load cover 40 may be rotated 90 degrees to position one first side panel 60 facing towards the container wall 14 and the other first side panel 60 facing towards the end 18 of the shipping container 10.

Other combinations of first side panels 60, second side panels 70, and third side panels 80 are also contemplated. One or more of the unitized loads 20 loaded into a shipping container 10 may have a unitized load cover 40 that has a different configuration than the unitized load covers 40 of the other unitized loads 20 in the shipping container 10. For example, a plurality of unitized loads 20 in the shipping container 10 may have unitized load covers 40 having the configuration shown in FIG. 8, which has two first side panels 60, one second side panel 70, and one third side panel 80. The last two unitized loads 20 loaded onto the shipping container 10 and positioned proximate the end 18 may have unitized load covers 40 having the configuration shown in FIG. 7, which includes two first side panels 60 and two second side panels 70. Other combinations of unitized load covers 40 on unitized loads 20 within a single shipping container 10 are contemplated.

Referring now to FIG. 9, the unitized load cover 40 may further include one or a plurality of top flaps 90. The top flaps 90 may be coupled and/or coupleable to a top panel 50 of the unitized load cover 40 proximate the edges 56 of the top panel 50 and may extend laterally outward (e.g., in the +/−X or +/−Y direction of the coordinate axis in FIG. 9) from the top panel 50. In some embodiments, the top flaps 90 may be coupled and/or coupleable to the top panel 50 by one or more of stitching, adhesives, bonding, fasteners, or combinations of these. Fasteners may include hook and loop fasteners, zippers, buttons, snaps, magnetic strips, pins, tie straps, or any other suitable fastener, or combinations of fasteners known in the art. In some embodiments, the top flaps 90 may be a separate piece from the unitized load cover 40 and may be removeably coupleable to the top panel 50 of the unitized load cover 40 by one or more of the fasteners previously described herein. The top flaps 90 may be flexible so that the top flaps 90 can be moved into and out of contact with the unitized load covers 40 of adjacent unitized loads 20 (e.g., neighboring unitized loads 20 adjacent in a side-to-side and/or front-to-back relationship). The top flaps 90 may be removeably coupleable to the top panel 50 of the adjacent unitized load cover 40 by any of the methods of coupling previously described.

Referring now to FIG. 10, the top flaps 90 may be operable to cover a gap between unitized loads 20 to prevent or reduce intrusion of air from the headspace 12 of the shipping container 10 into the gap between unitized loads 20. Intrusion of air from the headspace 12 of the shipping container 10 into the gaps between unitized loads 20 may increase the heat flux by convection into the goods 24. Referring again to FIG. 9, in some embodiments, the top panel 50 of the unitized load cover 40 may include the top flap 90 operable to cover the gap between the unitized load cover 40 and a second unitized load cover 40 placed on an adjacent unitized load 20 (adjacent in the +/−X or the +/−Y directions of the coordinate axis of FIG. 9). In some embodiments, the unitized load covers 40 may include a plurality of top flaps 90, each of which may be positioned proximate a different edge 56 of the top panel 50 so that the top flaps 90 can cover the gaps between unitized loads 20 on multiple sides of the unitized load 20.

Referring again to FIG. 9, the unitized load cover 40 may include one or a plurality of side flaps 92 coupled to the first side panel 60, the second side panel 70, the third side panel 80, or combinations of these. The side flaps 92 may be coupled and/or coupleable to the first side panel 60, the second side panel 70, and/or the third side panel 80 by one or more of stitching, adhesives, bonding, fasteners, or combinations of these. Fasteners may include hook and loop fasteners, zippers, buttons, snaps, magnetic strips, pins, tie straps, or any other suitable fastener, or combinations of fasteners known in the art. In some embodiments, the side flaps 92 may be a separate piece from the unitized load cover 40 and may be removeably coupleable to the first side panels 60, the second side panels 70, and/or the third side panels 80 by one or more of the fasteners previously described herein. The side flap 92 may extend laterally outward (e.g., in the +/−X or +/−Y direction of the coordinate axis in FIG. 9) from the first side panel 60, the second side panel 70, and/or the third side panel 80. The side flaps 92 may be flexible so that the side flaps 92 can be moved into and out of contact with the unitized load covers 40 of adjacent unitized loads 20 (e.g., neighboring of goods 20 adjacent in a side-to-side and/or front-to-back relationship). The side flaps 92 may be held in place by one or more fasteners previously described herein (not shown). Referring now to FIG. 11, the side flaps 92 may be operable to cover a gap between unitized loads 20 to prevent or reduce intrusion heat from the container walls 14 and/or heated air from the ends 18 of the shipping container 10 into the vertical gaps between unitized loads 20. Intrusion of heat or hot air from the container walls 14 and/or ends 18 of the shipping container 10 into the gaps between unitized loads 20 may increase the heat flux into the goods 24. Referring again to FIG. 9, the side flaps 92 may be positioned to cover the gap between unitized loads 20 arranged side-by-side in the +/−X direction within the shipping container 10 or side-by-side in the +/−Y direction (end to end) direction within the shipping container 10, according to the coordinate axis of FIG. 9.

Referring again to FIG. 9, in some embodiments, the unitized load covers 40 may include a strap 94 proximate a bottom edge of the first side panels 60, second side panels 70, and, when present, the third side panels 80. The strap 94 may be operable to tighten or cinch the bottom portion of the unitized load cover 40 against the pallet 22 or the bottom of the unitized load 20 to prevent hot air from flowing up between the unitized load cover 40 and the unitized load 20. The strap 94 may additionally be operable to tie up the unitized load cover 40 into a smaller package for return shipment of the unitized load cover 40 to the user. Additionally or alternatively, the unitized load covers 40 may include an elastic band around the bottom portions of the side panels 60, 70, 80, the elastic band being operable to hold the bottom portion of the unitized load covers 40 against the unitized load 20 (against either the pallet 22 or the goods 24).

The unitized load covers 40 may include various features for facilitating handling and installation of the unitized load covers 40. In some embodiments, the unitized load covers 40 may include a fastening strip 96 proximate the vertical edges 62, 72, 82 of the first side panels 60, second side panels 70, and/or third side panels 80. The fastening strips 96 may be operable to couple each of the side panels 60, 70, 80 together along the vertical edges 62, 72, 82 to form the unitized load cover 40. Although not shown, the fastening strips 96 may also be positioned proximate the top edge 61, 71, 81 of the side panels 60, 70, 80 or proximate the edges 56 of the top panel 50 and may be operable to couple the side panels 60, 70, 80 to the top panel 50. The fastening strips 96 may include magnetic strips, zippers, hook and loop strips, snaps, ties, or other fasteners. In some embodiments, the unitized load covers 40 may include lugs or hooks for facilitating easy installation/removal of the unitized load covers 40 from the unitized loads 20.

The unitized load covers 40 may be produced by producing each of the top panel 50, first side panels 60, the second side panels 70, and the third side panels 80 according to methods well known in the art. Each of the top panel 50, first side panels 60, second side panels 70, and, when present, third side panels 80 may be coupled together as previously described herein. Alternatively or additionally, in some embodiments fastening strips or fasteners may be added to the top panel 50, first side panels 60, second side panels 70, and, when present, the third side panels 80, for coupling the side panels 60, 70, 80 to the top panel 50 and to each other.

Referring again to FIG. 3B, in some embodiments, a unitized load assembly may include the pallet 22, one or a plurality of goods 24 supported on the pallet 22, and the unitized load cover 40 of the present disclosure. The plurality of goods 24 and at least a portion of the pallet 22 may be disposed within the cavity defined by the unitized load cover 40. The unitized load cover 40 may have any of the features, characteristics, or attributes previously described in the present disclosure for the unitized load cover 40. For example, the unitized load cover 40 can include the top panel 50, at least one first side panel 60 coupled to the top panel 50 and extending downward from the top panel 50, and at least one second side panel 70 coupled to the top panel 50 and extending downward from the top panel 50. The at least one second side panel 70 may be positioned next to or across from the at least one first side panel 60. An average thickness of the first side panel 60 may be different from an average thickness of the second side panel 70, where the average thickness of a panel may be a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel. The at least one first side panel 60, the at least one second side panel 70, and the top panel 50 may define a cavity configured to receive one unitized load 20. The good 24 may include a plurality of goods contained within a flexible intermediate bulk container. For example, in some embodiments, the goods 24 of the unitized load 20 may include a plurality of polymer pellets contained within a plurality of boxes, a plurality of bags, or a flexible intermediate bulk container.

The present disclosure may also include a method of thermally insulating a unitized load 20 using any of the unitized load covers 40 previously described in the present disclosure. In some embodiments, a method of thermally insulating a unitized load 20 during shipment or storage in a shipping container 10 may include providing any of the unitized load cover 40 previously described in the present disclosure, and placing the unitized load cover 40 over the unitized load 20 so that the unitized load 20 is at least partially disposed within the cavity defined by the unitized load cover 40. The unitized load cover 40 may be arranged so that, when the unitized load 20 is loaded into the shipping container 10, the at least one first side panel 60 of the unitized load cover 40 faces in a direction towards the container wall 14 and away from an adjacent unitized load 20 that is placed side-by-side with the unitized load 40. The at least one first side panel 60 may be operable to reduce heat transfer/heat flux from the container wall 14 of the shipping container 10 through the unitized load cover 40, thereby thermally insulating the unitized load 20.

In some embodiments, a method of thermally insulating a unitized load 20 during shipment in a shipping container 10 may include placing a unitized load cover 40 over the unitized load 20 so that the unitized load 20 is disposed within a cavity defined by the unitized load cover 40. The unitized load cover 40 may have any of the features, characteristics, or attributes previously described herein for the unitized load cover 40. The unitized load cover 40 can include the top panel 50, at least one first side panel 60 coupled to the top panel 50 and extending downward from the top panel 50, and at least one second side panel 70 coupled to the top panel 50 and extending downward from the top panel 50. The top panel 50, first side panels 60, and second side panels 70 may have any of the features, characteristics, or attributes previously described for the top panel 50, first side panels 60, and second side panels 70. The at least one second side panel 70 may be positioned next to or across from the at least one first side panel 60. An average thickness of the first side panels 60 may be different from an average thickness of the second side panels 70, where the average thickness of a panel may be a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel. The at least one first side panel 60, the at least one second side panel 70, and the top panel 50 may define a cavity configured to receive one unitized load 20. The unitized load cover 40 may be arranged so that, when the unitized load 20 is loaded into the shipping container 10, the at least one first side panel 60 of the unitized load cover 40 faces in a direction towards the container wall 14 and away from an adjacent unitized load 20 that is placed side-by-side with the unitized load 40. The at least one first side panel 60 may be operable to reduce heat transfer/heat flux from the container wall 14 of the shipping container 10 through the unitized load cover 40, thereby thermally insulating the unitized load 20.

The method may further include engaging the strap 94 at the bottom portion of the first side panels 60 and second side panels 70 to secure the first side panels 60 and second side panels 70 against the unitized load 20, thereby reducing hot air penetration between the unitized load cover 40 and the unitized load 20. The method may further include loading a plurality of the unitized loads 20 having the unitized load covers 40 installed thereon into a shipping container 10. The method may further include coupling a top flap 90 of the unitized load cover 40 to a top panel 50 of the unitized load cover 40 on an adjacent unitized load 20 to cover the top gap between the two unitized loads 20. The method may further include coupling a side flap 92 of the unitized load cover 40 to a side panel 60, 70, 80 of the unitized load cover 40 on an adjacent unitized load 20 to cover a side gap between the two unitized loads 20.

A first aspect of the present disclosure may include a unitized load cover that comprises a top panel, at least one first side panel coupled to the top panel and extending downward from the top panel, and at least one second side panel coupled to the top panel and extending downward from the top panel. The at least one second side panel may be next to or across from the at least one first side panel. An average thickness of the at least one first side panel is different from an average thickness of the at least one second side panel, where the average thickness of a panel is a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel. The at least one first side panel, the at least one second side panel, and the top panel define a cavity configured to receive at least one unitized load.

A second aspect of the present disclosure may include a unitized load assembly comprising a pallet, a load supported on the pallet, and a unitized load cover. The load and at least a portion of the pallet may be disposed within the unitized load cover, and the load may include boxes, bags, or a flexible intermediate bulk container containing one or more goods. The unitized load cover may include a top panel, at least one first side panel coupled to the top panel and extending downward from the top panel, and at least one second side panel coupled to the top panel and extending downward from the top panel. The at least one second side panel may be next to or across from the at least one first side panel. An average thickness of the at least one first side panel is different from an average thickness of the at least one second side panel, where the average thickness of a panel is a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel. The at least one first side panel, the at least one second side panel, and the top panel define a cavity configured to receive at least one unitized load. In some embodiments, the goods may include polymer pellets contained in the boxes, bags, or flexible intermediate bulk containers.

A third aspect of the present disclosure may include a method of thermally insulating a unitized load during shipment, the method comprising placing a unitized load cover over the unitized load so that the unitized load is disposed within a cavity defined by the unitized load cover. The unitized load cover may include a top panel, at least one first side panel coupled to the top panel and extending downward from the top panel, and at least one second side panel coupled to the top panel and extending downward from the top panel. The at least one second side panel may be next to or across from the at least one first side panel. An average thickness of the at least one first side panel is different from an average thickness of the at least one second side panel, where the average thickness of a panel is a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel. The at least one first side panel, the at least one second side panel, and the top panel define a cavity configured to receive at least one unitized load. The unitized load cover may be arranged on the unitized load so that, when the unitized load is loaded into a shipping container, the at least one first side panel of the unitized load cover faces towards a container wall of the shipping container. The at least one first side panel may be operable to reduce heat transfer from the container wall or an interior of the shipping container through the unitized load cover, thereby thermally insulating the unitized load.

A fourth aspect of the present disclosure may include any of the first through third aspects, wherein the average thickness of the at least one first side panel may be greater than the average thickness of the at least one second side panel.

A fifth aspect of the present disclosure may include any of the first through fourth aspects, wherein a ratio of the average thickness of the at least one first side panel divided by the average thickness of the at least one second side panel may be greater than or equal to 1.25, or greater than or equal to 1.5, or even greater than or equal to 2.0.

A sixth aspect of the present disclosure may include any of the first through fifth aspects, wherein an average thickness of the top panel is the same as the average thickness of the at least one first side panel or the average thickness of the at least one second side panel.

A seventh aspect of the present disclosure may include any of the first through fifth aspects, wherein the top panel has an average thickness greater than or equal to the average thickness of the at least one first side panel and the average thickness of the at least one second side panel.

An eighth aspect of the present disclosure may include any of the first through seventh aspects, comprising two first side panels and two second side panels.

A ninth aspect of the present disclosure may include the eighth aspect, wherein the two first side panels are coupled together along a vertical edge of each of the two first side panels and the two second side panels are coupled together along a vertical edge of each of the two second side panels.

A tenth aspect of the present disclosure may include any of the first through ninth aspects, further comprising at least one third side panel coupled to the top panel and extending downward from the top panel, wherein an average thickness of the at least one third side panel is different from the average thickness of the at least one first side panel and the average thickness of the at least one second side panel.

An eleventh aspect of the present disclosure may include any of the first through tenth aspects, wherein the top panel, the at least one first side panel, the at least one second side panel, or combinations of these, comprises a multi-layer structure that includes at least one structural layer and at least one insulating media layer.

A twelfth aspect of the present disclosure may include any of the first through eleventh aspects, wherein the top panel, the at least one first side panel, the at least one second side panel, or combinations of these, include a reflective layer or a reflective coating.

A thirteenth aspect of the present disclosure may include any of the first through twelfth aspects, wherein the top panel, the at least one first side panel, the at least one second side panel, or combinations of these, include a reduced-friction layer or a reduced-friction coating operable to reduce a coefficient of friction between the unitized load cover and the container wall, an adjacent unitized load cover, and/or the unitized load contained within the cavity of the unitized load cover.

A fourteenth aspect of the present disclosure may include any of the first through thirteenth aspects, wherein one of the top panel, the at least one first side panel, or the at least one second side panel comprises an insulating media layer that is different from an insulating media layer of the other ones of the top panel, first side panel, and second side panel.

A fifteenth aspect of the present disclosure may include any of the first through fourteenth aspects, wherein the top panel comprises a top flap operable to cover a gap between the unitized load cover and an adjacent unitized load cover placed directly next to the unitized load cover.

A sixteenth aspect of the present disclosure may include any of the first through fifteenth aspects, wherein the at least one first side panel, or the at least one second side panel, or both, comprises a side flap operable to cover a gap between two side-by-side unitized load covers.

A seventeenth aspect of the present disclosure may include any of the first through sixteenth aspects, further comprising a strap proximate a bottom edge of the at least one first side panel and the at least one second side panel, the strap operable to tighten a bottom portion of the unitized load cover against the unitized load.

An eighteenth aspect of the present disclosure may include any of the first through seventeenth aspects, wherein the at least one first side panel and the at least one second side panel are removeably coupleable to the top panel.

Throughout this disclosure ranges are provided for various properties of the unitized load covers 40. It will be appreciated that when one or more explicit ranges are provided the individual values and the ranges formed therebetween are also intended to be provided, as providing an explicit listing of all possible combinations is prohibitive. For example, a provided range of 1-10 also includes the individual values, such as 1, 2, 3, 4.2, and 6.8, as well as all the ranges which may be formed within the provided bounds, such as 1-8, 2-4, 6-9, and 1.3-5.6.

It should now be understood that various aspects of the unitized load covers are described and such aspects may be utilized in conjunction with various other aspects. It should also be understood to those skilled in the art that various modifications and variations can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various described embodiments provided such modification and variations come within the scope of the appended claims and their equivalents. 

1. A unitized load cover comprising: a top panel; at least one first side panel coupled to the top panel and extending downward from the top panel; and at least one second side panel coupled to the top panel and extending downward from the top panel, wherein: the at least one second side panel is next to or across from the at least one first side panel; an average thickness of the at least one first side panel is different from an average thickness of the at least one second side panel, where the average thickness of a panel is a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel; and the at least one first side panel, the at least one second side panel, and the top panel define a cavity configured to receive at least one unitized load.
 2. The unitized load cover of claim 1, wherein the average thickness of the at least one first side panel is greater than the average thickness of the at least one second side panel.
 3. The unitized load cover of claim 1, wherein a ratio of the average thickness of the at least one first side panel divided by the average thickness of the at least one second side panel is greater than or equal to 1.25.
 4. The unitized load cover of claim 1, wherein an average thickness of the top panel is the same as the average thickness of the at least one first side panel or the average thickness of the at least one second side panel.
 5. The unitized load cover of claim 1, wherein the top panel has an average thickness greater than or equal to the average thickness of the at least one first side panel and the average thickness of the at least one second side panel.
 6. The unitized load cover of claim 1, comprising two first side panels and two second side panels.
 7. The unitized load cover of claim 6, wherein the two first side panels are coupled together along a vertical edge of each of the two first side panels and the two second side panels are coupled together along a vertical edge of each of the two second side panels.
 8. The unitized load cover of claim 1, further comprising at least one third side panel coupled to the top panel and extending downward from the top panel, wherein an average thickness of the at least one third side panel is different from the average thickness of the at least one first side panel and the average thickness of the at least one second side panel.
 9. The unitized load cover of claim 1, wherein the top panel, the at least one first side panel, the at least one second side panel, or combinations of these, comprises a multi-layer structure that includes at least one structural layer and at least one insulating media layer.
 10. The unitized load cover of claim 1, wherein the top panel, the at least one first side panel, the at least one second side panel, or combinations of these, include a reflective layer, a reflective coating, a reduced-friction layer, or a reduced-friction coating.
 11. The unitized load cover of claim 9, wherein one of the top panel, the at least one first side panel, or the at least one second side panel comprises an insulating media layer that is different from an insulating media layer of the other ones of the top panel, first side panel, and second side panel.
 12. The unitized load cover of claim 1, wherein the top panel comprises a top flap operable to cover a gap between the unitized load cover and an adjacent unitized load cover placed directly next to the unitized load cover.
 13. The unitized load cover of claim 1, wherein the at least one first side panel, the at least one second side panel, or both, comprises a side flap operable to cover a gap between two side-by-side unitized load covers.
 14. A unitized load assembly comprising a pallet, a load supported on the pallet, and the unitized load cover of claim 1, wherein the load and at least a portion of the pallet are disposed within the unitized load cover and the load comprises boxes, bags, or a flexible intermediate bulk container containing one or more goods.
 15. A method of thermally insulating a unitized load during shipment, the method comprising: placing a unitized load cover over the unitized load so that the unitized load is disposed within a cavity defined by the unitized load cover, the unitized load cover comprising: a top panel; at least one first side panel coupled to the top panel and extending downward from the top panel; and at least one second side panel coupled to the top panel and extending downward from the top panel, wherein: the at least one second side panel is next to or across from the at least one first side panel; an average thickness of the first side panel is different from an average thickness of the second side panel, where the average thickness of a panel is a distance between an outside surface and an inside surface of the panel averaged over a surface area of the panel; and the at least one first side panel, the at least one second side panel, and the top panel define a cavity configured to receive one unitized load, wherein: the unitized load cover is arranged on the unitized load so that, when the unitized load is loaded into a shipping container, the at least one first side panel of the unitized load cover faces towards a container wall of the shipping container; and the at least one first side panel is operable to reduce heat transfer from the container wall or an interior of the shipping container through the unitized load cover, thereby thermally insulating the unitized load. 